Fablok Mills Inc. - Process - Knitting, Dyeing & Finishing

Fablok Mills Inc. - Knitting, Dyeing & Finishing - Service you Can Count On!

Fablok Mills Inc. - Knitting, Dyeing & Finishing - Service you Can Count On! We specialize in nylon mesh, polyester mesh and polypropylene mesh.

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Processes

Fablok Warp Knitting

Yarn is supplied from a beam. Latch needles are used. Each needle has its own yarn. Needles are fixed in a moveable bar. All needles knit at the same time (parallel knitting cycle). Many individual yarns in each course fabric is formed along the wales. Fabric is made in a flat form. Each machine revolution produces one course (row) of stitches.
Production rate=machine rpm
Fabric is relatively stable (dimensionally). Tricot and Raschel are examples.

Basic Principles of Production

F iber Base | Denier | Spinneret | Melt Spinning | Stretching & Orientation

THE FIBER BASE

Most man-made fibers are formed by forcing a syrupy substance (about the consistency of honey) through the tiney holes of a device called a spinneret.

In their orignial state the fiber-forming substances exist as solids and therefore must be first converted into a liquid state for extrusion. This is achieved by dissolving them in a solvent or melting them with heat. If they cannot be dissolved or melted directly, they must be chemically converted into coluble derivatives.

The basic substance for the three cellulosic fibers (acetate, rayon and triacetate) is cellulose which comes from purified wood pulp. It can be dissolved for extrusion into fibers. The substances used in the production of the noncellulosic fibers generally are melted or chemically converted into a liquid state.

DENIER NATURAL

Unlike natuarl fibers, the man-mades can be extruded in different thicknesses. This is called denier. It is the industry's word for measuring the size of a continuous monofilament, a multifilament yarn or cut staple fiber.

Fifteen (15)-denier monofilament is commonly used in pantyhose to achieve ultimate sheerness. Yarns of 840-denier are used in tires for trucks, auto mobiles, planes and other vehicles, giving greater strength. Incidentally, one pound of 15-denier yarn is 169 miles long, and one pound of 840-denier yarn in only 3 miles long.

THE SPINNERET

The spinneret, which is used in the production of all man-made fibers, is similar in principle to the shower head in your bathroom...Liquid is forced through the holes. A spinneret can have from one to literally thousands of tiny holes and is generally made from very expensive corrosion-resistant metals.

The filaments emerging from the holes in the spinneret are then hardened or solidified. The process of extrusion and hardening is called spinning, not to be confused with the textile operation of the same name. There are three methods of spinning man-made gibers: wet, dry and melt spinning. Some fibers may be produced by more than one method.

MELT SPINNING

When the fiber-forming substance is melted for extrusion and hardened by cooling, the process is called melt spinning. Nylon, olefin, polyester, aramld and glass are produced by the melt spinning process.

STRETCHING AND ORIENTATION

While the fibers are hardening, or after they have been hardened, the fibers are stretched. This reduces the fiber diameter, or denier, and causes the molecules in the fiber to arrange themselves into a more orderly pattern. In a given fiber type, the strength increases and the fiber's ability to stretch without breaking decreases as the pattern of the molecular arrangement becomes more orderly, or better oriented. A wide range of strength/stretch combinations may be produced in this way.